Engine Assembly Removal

Запустите двигатель.

Переведите выключатель системы кондиционирования в положение ON (ВКЛ).

Включите компрессор системы кондиционирования при частоте вращения коленчатого вала двигателя около 1000 об/мин на 5-6 мин., чтобы прокачать хладагент и собрать оставшееся в компонентах компрессорное масло в компрессоре.

Выключите двигатель.

С помощью SST выпустите газообразный хладагент.

Специальный инструмент (SST):

07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

Remove the 4 bolts, 12 clips and under cover.

Remove the 2 clips and under cover.

Remove the 2 clips and under cover.

Remove the 2 clips and under cover.

Remove the nut, bolt, 3 clips and floor cover.

Loosen the radiator drain cock plug.

УКАЗАНИЕ:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Remove the radiator reservoir cap.

ПРЕДОСТЕРЕЖЕНИЕ:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the cylinder block drain cock plug.

Remove the oil filler cap.

Remove the clip and open the oil pan drain service cover.

Remove the oil drain plug and gasket, and drain the engine oil into a container.

Remove the filler plug and gasket.

Remove the drain plug and gasket, and drain the oil.

Install a new gasket and the drain plug.

Момент затяжки:

49 Н*м{500 кгс*см, 36 фунт-сила-футов}

Remove the drain plug and gasket, and drain the oil.

Install a new gasket and the drain plug.

Момент затяжки:

49 Н*м{500 кгс*см, 36 фунт-сила-футов}

Выверните 4 болта и снимите капот.

Detach the 4 clips and remove the engine cover.

Снимите 2 фиксатора.

Частично снимите крышку кронштейна радиатора.

УКАЗАНИЕ:

Нет необходимости снимать крышку кронштейна радиатора полностью. Частично снимите ее так, чтобы можно было снять накладку бампера.

Remove the bolt and loosen the nut.

Detach the 2 wire harness clamps.

Detach the hook of the battery clamp from the battery bracket front, and then remove the battery clamp.

Detach the 2 wire harness clamps.

Remove the 4 bolts and bracket front.

Remove the 2 bolts and bracket reinforcement.

Disconnect the mass air flow meter connector.

Disconnect the wire harness clamp.

Unhook the 3 hook clamps, and then remove the air cleaner cap.

Remove the air cleaner filter element from the air cleaner case.

Disconnect the wire harness clamp and remove the 3 bolts and air cleaner case.

Disconnect the level warning switch connector.

Disconnect the 4 hoses indicated in the illustration.

Remove the bolt and fuel filter.

Remove the glow plug relay.

Disconnect the fuel filter level switch connector.

Disconnect the 2 wire harness clamps.

Disconnect the 2 fuel hoses from the bracket.

Remove the 3 bolts and bracket.

Remove the engine room junction block cover (upper).

Remove the nut and disconnect the engine room junction block cover (side) with 3 connectors and wire.

Remove the nut and disconnect the starter wire.

Disconnect the 2 injector driver connectors.

Disconnect the vacuum pump hose.

Disconnect the 2 fuel hoses.

Disconnect the 2 heater hoses.

Disconnect the 2 ECM connectors.

Remove the 3 bolts, vacuum switching valve bracket and vacuum transmitting pipe.

Remove the 3 bolts holding the ECM brackets.

Disconnect the 2 ECM connectors.

1. Raise the 2 levers while pushing the locks on the 2 levers, and remove the 2 ECM connectors.
   

Remove the ECM.

Remove the 4 screws and 2 ECM brackets.

Remove the 2 bolts and reservoir.

Remove the front bumper (see page RAV4_ACA30 RM0000015RJ004X.html).

Отсоедините 2 разъема звукового сигнала.

Выверните 2 болта и снимите усилитель.

Выверните 2 болта и снимите 2 кронштейна.

Снимите конденсатор системы кондиционирования.

Выверните 3 болта и снимите защелку замка капота.

Remove the 4 bolts and radiator support upper.

Disconnect the inlet radiator hose from the engine.

Disconnect the outlet radiator hose from the engine.

Loosen the 2 clamps.

Disconnect the No. 2 and No. 3 air hoses from the engine.

Remove the radiator (with intercooler) from the vehicle.

Loosen the 2 clamps.

Remove the bolt.

Remove the No. 2 air tube from the intercooler and No. 3 air hose.

Loosen the clamp. Remove the No. 2 air hose from the intercooler.

Remove the 4 bolts, and then separate the intercooler and radiator.

Выверните болт и отсоедините трубопровод высокого давления на выходе компрессора от компрессора системы кондиционирования.

Снимите кольцевое уплотнение с трубопровода высокого давления на выходе компрессора.

ПРИМЕЧАНИЕ:

Для предотвращения проникновения влаги и загрязняющих веществ герметизируйте отверстия отсоединенных деталей с помощью виниловой ленты.

Выверните болт и отсоедините трубопровод низкого давления кондиционера от компрессора системы кондиционирования.

Снимите кольцевое уплотнение с трубопровода низкого давления кондиционера.

ПРИМЕЧАНИЕ:

Для предотвращения проникновения влаги и загрязняющих веществ герметизируйте отверстия отсоединенных деталей с помощью виниловой ленты.

Remove the 2 clips and disconnect the cable ends of the control cable.

Using a screwdriver, release the cable locks of the shift cable and select cable.

Turn the lock nuts 180° counterclockwise and hold them in that position. Remove the shift cable and select cable while holding them.

Remove the shift cable from the floor shift shift lever assembly while holding the lock nut.

Repeat the step above for the select cable.

ПРИМЕЧАНИЕ:

Do not push in the cable locks.

Disconnect the 5 bolts, release cylinder and flexible hose bracket.

Remove the 2 bolts and 2 compression springs.

Disconnect the 3 exhaust pipe supports, and remove the front exhaust pipe.

Remove the gasket from the exhaust manifold.

Отверните 2 болта, снимите 2 регулировочные шайбы и отсоедините карданный вал с валом центрального подшипника.

ПРИМЕЧАНИЕ:

1. При разборке не прилагайте избыточных усилий к карданному шарниру.
   
2. При демонтаже, транпортировке и хранении карданного вала с валом центрального подшипника на допускайте, чтобы угол шарнира № 2 был больше 20°.
   

Нанесите сборочные метки на корпус дифференциала и карданный вал.

Отверните 4 гайки, снимите 4 шайбы и отсоедините карданный вал и корпус дифференциала.

Нанесите сборочные метки на раздаточную коробку и карданный вал.

Отверните 4 гайки, снимите 4 шайбы и отсоедините карданный вал от раздаточной коробки.

С помощью SST и молотка раскерните накерненную часть гайки.

Специальный инструмент (SST):

09930-00010

ПРИМЕЧАНИЕ:

Полностью освободите накерненную часть гайки, иначе можно повредить винт приводного вала.

Нажав на тормоз, снимите стопорную гайку ступицы колеса.

Отверните 2 гайки и снимите стойку стабилизатора.

Remove the stabilizer link (see page RAV4_ACA30 RM00000228C000X_01_0010.html).

(see page RAV4_ACA30 RM000000UNK00DX_01_0054.html).

Снимите шплинт и корончатую гайку.

При помощи SST отсоедините наконечник тяги от поворотного кулака.

Специальный инструмент (SST):

09628-62011

ПРИМЕЧАНИЕ:

Не допускайте повреждения пылезащитной крышки рулевой тяги.

Remove the drive shaft (see page RAV4_ACA30 RM00000226Q000X.html).

Remove the drive shaft (see page RAV4_ACA30 RM00000226Q000X.html).

Install the No. 1 and No. 2 engine hangers with the 2 bolts as shown in the illustration.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

УКАЗАНИЕ:

1. Insert the claw of the No. 1 engine hanger into hole of the cylinder head.
   
2. Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.
   

Install an engine sling device to the engine and hold the engine with a chain block.

ПРЕДОСТЕРЕЖЕНИЕ:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

Set an engine lifter underneath the engine.

Remove the column hole cover. Loosen the bolt holding the intermediate shaft, and slide the intermediate shaft.

Put matchmarks on the intermediate shaft and pinion.

Remove the 2 bolts and 2 nuts and disconnect the engine mounting insulator RH.

Remove the bolt and nut, and disconnect the engine mounting insulator LH.

Remove the 6 bolts and the front suspension member brace rear RH and LH.

Remove the 6 bolts, crossmember and suspension member.

Using the chain block, slowly remove the engine from the vehicle and the intermediate shaft from the pinion. Then set the engine on the engine lifter.

ПРИМЕЧАНИЕ:

1. Make sure that the engine is clear of all wiring and hoses.
   
2. While lowering the engine from the vehicle, do not allow it to contact the vehicle.
   

УКАЗАНИЕ:

Place the engine on wooden blocks or equivalent so that the engine is level.

Remove the sling device from the engine.

Install a chain block.

Remove the bolt, nut and crossmember.

Remove the bolt and suspension crossmember.

Remove the 2 bolts and disconnect the wire harness.

Remove the 2 bolts and loosen the 2 clamps.

Remove the No. 1 air tube.

Remove the engine wire from the engine.

Disconnect the starter connector.

Open the terminal cap, remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the 4 bolts and stiffener plate from the engine and transaxle assembly.

Remove the 4 bolts and stiffener plate from the engine and transaxle assembly.

Remove the 5 bolts.

Separate and remove the transaxle from the engine.

Hold the crankshaft with SST.

Специальный инструмент (SST):

09213-58013
09330-00021

Using a T55 "torx" socket wrench, remove the 8 bolts and the flywheel.

Remove the sling device and chain block from the engine.

Using SST and 22 mm wrench, rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the V-ribbed belt.

Специальный инструмент (SST):

09216-42010

ПРИМЕЧАНИЕ:

Make sure SST is installed as shown in the illustration. If not, SST and/or the V-ribbed belt may not be able to be removed.

Отсоедините разъем.

Без шпильки:
Выверните 4 болта и снимите компрессор системы кондиционирования.

При наличии шпильки:
Выверните 3 болта, отверните гайку и снимите компрессор системы кондиционирования.

Disconnect the generator connector.

Remove the terminal cap.

Remove the nut and bolt, and disconnect the generator wire.

Remove the 3 bolts and generator.

Remove the bolt, plate and idler pulley.

Using a screwdriver, remove the idler pulley cover plate.

Remove the bolt and idler pulley.

Remove the 4 bolts, 2 nuts and engine mounting bracket.

Remove the 3 bolts and tensioner.

Отсоедините 2 вакуумных шланга.

Выверните 3 болта и снимите вакуумный насос.

Снимите 2 кольцевых уплотнения с вакуумного насоса.

Disconnect the fuel temperature sensor connector.

Disconnect the suction control valve connector.

Remove the 2 bolts to remove the supply pump, O-ring and supply pump drive coupling from the cylinder head.

Remove the O-ring from the supply pump.

Remove the 2 bolts and oil dipstick guide.

Remove the O-ring from the dipstick guide.

Remove the 2 bolts.

Remove the 2 nuts, EGR pipe and 2 gaskets.

Disconnect the EGR valve connector.

Disconnect the EGR valve connector.

Remove the 2 bolts, EGR valve and gasket.

Remove the bolt and pressure sensor.

Remove the 2 bolts and engine cover bracket.

Remove the common rail (see page RAV4_ACA30 RM0000015BX002X.html).

Remove the injector (see page RAV4_ACA30 RM0000015BP002X.html).

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 nuts and 2 bolts, and then remove the diesel throttle body and gasket.

Remove the 7 bolts, 2 nuts, intake manifold and gasket.

Disconnect the oil cooler hose.

Remove the 5 bolts, 3 O-rings and oil cooler.

Remove the engine coolant temperature sensor.

Remove the 2 bolts, O-ring and by-pass pipe.

Remove the 2 union bolts, 2 gaskets and oil pipe.

Remove the 6 bolts, nut and oil cooler bracket.

Remove the 3 O-rings.

Remove the 2 bolts, O-ring and by-pass pipe.

Disconnect the hose.

Remove the 3 nuts, gasket and inlet housing.

Remove the 5 grommets.

Remove the 5 nuts and glow plug connector.

Remove the 4 glow plugs.

Remove the turbocharger (see page RAV4_ACA30 RM0000019S8007X.html).

Remove the 3 bolts and bearing bracket.

Disconnect the vacuum hose from the No. 2 EGR valve.

Remove the 4 bolts.

Remove the 2 bolts, 2 nuts, EGR cooler, 2 gaskets and O-ring.

Remove the 2 bolts and 2 nuts.

Disassemble the No. 1 EGR pipe, No. 2 EGR valve, EGR cooler and 2 gaskets.

Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

Remove the 4 bolts and level sensor.